Floating Vacuum Head Array for Curved Preform Placement and Compaction
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Solution Overview
Problem
The placement of large preforms onto complex, curved rigid tools is challenging due to peeling or shifting issues, and existing methods require the entire layup to be completed before compaction, especially when using materials like tacky tape that are not compatible with uncured composite materials.
Innovation Solution
A high-volume vacuum securement head with adjustable end effectors that can pick, place, and compact multiple objects simultaneously onto complex surfaces, using a strongback with impermeable membranes and a vacuum system to create a suction hold, allowing for securement and compaction without the need for additional sealing materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional placement methods are used for large preforms on complex surfaces, then the preforms can be placed on the tool, but the preforms are prone to peeling or shifting during or after placement
Solution Approach 1:
The vacuum head is divided into multiple independent vacuum cups arranged in an array, each capable of independently securing portions of the preform. This segmentation allows distributed contact across the complex surface, preventing peeling and shifting while maintaining placement reliability without requiring a single complex sealing mechanism.
Solution Approach 2:
The vacuum head serves multiple functions simultaneously: it picks up the preform, transports it, places it on the complex surface, and applies compaction force. This multi-functionality eliminates the need for separate handling and sealing operations, resolving the contradiction between reliability and device complexity.
2Ease of manufacture
If tacky tape is used to secure the vacuum bag, then the vacuum bag can be attached to the rigid tool, but the tape cannot touch uncured composite material
Solution Approach 1:
The harmful tacky tape is extracted and replaced with a vacuum-based attachment system. The vacuum cups create secure attachment through suction alone, eliminating the need for adhesive materials that could contaminate uncured composite while maintaining ease of vacuum bag attachment.
Solution Approach 2:
The vacuum cup array acts as an intermediary between the vacuum bag and the preform/tool surface. Instead of using adhesive tape that contacts the composite, the vacuum system creates a mechanical suction bond through the cup array, preventing contamination while achieving secure attachment.
3Ease of manufacture
If the entire layup is completed before compaction, then materials like tacky tape can be used for sealing, but the process time is significantly increased
Solution Approach 1:
The vacuum cups are pre-positioned and activated before the complete layup is finished. This preliminary vacuum application secures the preform in place during the remaining layup operations, eliminating the need to wait for complete layup before compaction. The vacuum system performs the sealing action in advance, enabling continuous work and improving productivity.
Solution Approach 2:
The vacuum system maintains continuous securement throughout the entire process from preform placement through complete layup. This continuous action eliminates idle waiting time and allows the layup process to proceed without interruption, significantly improving productivity while maintaining ease of sealing through the vacuum mechanism.
4Manufacturing precision
If multiple objects are placed individually, then each object can be positioned precisely, but the placement process becomes time-consuming
Solution Approach 1:
Multiple vacuum cups are combined into a single array that can secure multiple preforms or different portions of a large preform simultaneously. This merging of multiple pickup points into one integrated vacuum head allows precise positioning of each object while placing them all at once, resolving the contradiction between manufacturing precision and productivity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables rapid and secure placement and compaction of objects on complex surfaces, improving efficiency and reducing the risk of peeling or shifting, while avoiding contact issues with uncured composite materials.
Implementation Method 1
a vacuum system configured to provide suction through the end effectors. The suction is configured to remove air between the impermeable membrane and a rigid tool
Implementation Method 2
The suction is configured to remove air between the impermeable membrane and a rigid tool, and offset air leaks between the impermeable membrane and the rigid tool
Data Source
AI summary
Systems and methods are provided for handling objects. One embodiment is an apparatus for handling objects. The apparatus includes a vacuum securement head. The vacuum securement head includes a strongback, and an array of end effectors arranged at the strongback in conformance with a contour. The contour is complementary to a pickup tool. The array of end effectors is configured to pickup objects at the pickup tool. The vacuum securement head also includes an impermeable membrane that is penetrated by the end effectors, and a vacuum system configured to provide suction through the end effectors. The suction is configured to remove air between the impermeable membrane and a rigid tool, and offset air leaks between the impermeable membrane and the rigid tool.